Dual layer sleeping pad

ABSTRACT

A dual layer inflatable sleeping pad has an upper inflatable layer coupled to a lower inflatable layer. The dual-layer sleeping pad has an inflation valve for the lower layer and a second inflation valve for the upper layer. These valves are in fluid communication with their respective layer, thereby allowing air to travel in and out of each layer as needed. Each layer is independent from one another and the inflation level of each layer can be independently adjusted.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 12/920,702 titled “Outdoor Equipment” filed on Sep. 2, 2010 and claims priority from PCT Application PCT/US2008/057682 titled “Outdoor Equipment” filed on Mar. 20, 2008 and U.S. Provisional Application Ser. No. 60/895,771 titled “Outdoor Equipment” which was filed on Mar. 20, 2007, all of which are incorporated fully herein by reference.

TECHNICAL FIELD

The present invention relates to camping equipment and more particularly, relates to dual layer, inflatable sleeping pads.

BACKGROUND INFORMATION

Current inflatable sleeping pads are composed of a fabric cover, which may include a single layer of soft foam bonded to the fabric cover. In order to decrease the feel of any rough terrain beneath a pad, a user typically blows/pumps more air into the pad. However, these heavily inflated sleeping pads are generally more uncomfortable to use. Even if air is reduced in the sleeping pad to increase a user's comfort, it is difficult to avoid the irritations caused by irregularities of the ground beneath the pad. Moreover, if there is a puncture in the single layer, the sleeping pad will fail given that there is no redundancy in the layers. Furthermore, a single layer pad provides little insulation between a user and the ground as cold temperatures from the ground are absorbed into the lower surface of the pad

Therefore, the prior art is lacking a sleeping pad that enables dual inflatable layers: a high pressure inflation layer located at the bottom of the sleeping pad against the ground to smooth out a rough terrain and then a second inflation layer along the top of the sleeping pad that can be adjusted for user comfort. Such a double-layer pad should not weigh more or pack with any greater volume than existing single layer sleeping pads.

SUMMARY

The present invention provides for a dual-layer, inflatable sleeping pad. This sleeping pad has an upper inflatable layer coupled to a lower inflatable layer. The upper and lower layers are independently inflatable to a selected inflation level separate from each other.

The present invention includes one inflation valve on the lower layer, in fluid communication with the lower inflatable layer. There is also a second valve located on the upper layer, in fluid communication with the upper inflatable layer. These two valves allow a user to independently adjust the air pressures in the upper and lower inflatable layers.

In one embodiment of the present invention, a dual-layer, inflatable sleeping pad comprises an upper inflatable layer, wherein the upper inflatable layer is configured for being inflatable to a first user-selected inflation level; a lower inflatable layer, coupled to the upper layer, wherein the lower inflatable layer is configured for being inflatable to a second user-selected inflation level independent of the first user selected inflation level; a first inflation valve located on the lower inflatable layer and in fluid communication with the lower inflatable layer and configured to allow air to travel into and out of the lower inflatable layer; and a second inflation valve, located on the upper inflatable layer and in fluid communication with the upper inflatable layer and configured to allow air to travel into and out of the upper inflatable layer.

The upper inflatable layer and the lower inflatable layer may further comprise an open cell foam material. The open cell foam material of the at least one of the upper and lower inflatable layers may include at least one hollow channel disposed through the open cell foam material.

The upper and lower inflatable layers may be coupled together using one of the methods selected from the group consisting of: a plurality of welded tabs, a plurality of semi-permanent, releasable fasteners and drop thread stitching.

The first and second inflation valves may be located on a same end of the upper and lower inflatable layers.

The lower inflatable layer has an upper surface and a lower surface, wherein the lower surface may be made from a durable and abrasion-resistant material. The upper inflatable layer has an upper surface and a lower surface, wherein the upper surface may be a soft, micro-fiber fabric material.

The sleeping pad may further comprise a separation layer, wherein the separation layer is located between the upper inflatable layer and the lower inflatable layer. The separation layer may be comprised of a metallic material. The separation layer may be comprised of an insulation material.

In alternate embodiments of the present invention, the upper layer comprises open cell foam and the lower layer comprises inflatable ribs. Alternatively, the upper layer comprises open cell foam and the lower layer comprises baffles.

The sleeping pad may comprise a middle layer disposed between the upper inflatable layer and the lower inflatable layer, the middle layer including metallic material.

In another embodiment of the present invention, one of the upper inflatable layer and the lower inflatable layer further comprise an open cell foam material.

It is important to note that the present invention is not intended to be limited to a system or method which must satisfy one or more of any stated objects or features of the invention. It is also important to note that the present invention is not limited to the preferred, exemplary, or primary embodiment(s) described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:

FIG. 1 is a perspective view of the dual-layer sleeping pad according to the present invention;

FIG. 2 is a side view of a dual-layer sleeping pad of the present invention.

FIG. 3 is a perspective view of a dual-layer sleeping pad according to the present invention;

FIG. 4 is a cross-sectional perspective view of a dual-layer sleeping pad according to the present invention;

FIGS. 5 a and 5 b are cross sectional views of two dual-layer sleeping pads according to the present invention;

FIGS. 6 a and 6 b are detailed views of the rib configuration and baffle configuration, respectively, according to the present invention.

FIG. 7 is a detailed view of a dual-layer sleeping pad according to the present invention; and

FIG. 8 is a detailed view of a dual-layer sleeping pad according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention consists of a sleeping pad 100, FIGS. 1 and 2, which is comprised of two discrete layers: an upper layer 102 and a lower layer 104. In one embodiment of the present invention, each layer 102 and 104 is comprised of an open-cell, foam material, enclosed within a nylon or similar enclosure, such that when an inflation valve is opened, the foam self inflates by absorbing ambient air. Other types of inflatable layers are contemplated by the invention, including a foamless, air containing layer. Each of these layers can be inflated to a different inflation level based on a user's preference. Therefore, a user may inflate the lower layer of the sleeping pad to a high pressure in order to minimize the feel of miscellaneous ground debris, rocks, or uneven terrain during sleeping. The upper layer may be independently inflated to a relatively lower pressure, in order to maximize the cushioning and comfort for the user.

The present invention further includes an upper layer valve 106 and a lower layer valve 108. The valves are preferably separately placed and the valves are in fluid communication with each respective layer, allowing for different inflation levels to be attained in each layer. Valves 106 and 108 allow air to travel into an inner cavity of each respective layer when opened. The user can further inflate each layer using an air pump or by blowing air into a respective air valve. Conversely, when the valves are closed, no air can enter or escape the cavity. As shown in FIG. 1, valves for each layer may be located on the same end of the sleeping pad in order to facilitate a quicker setup time although this is not a limitation of the present invention. For example, as shown in FIG. 2, valves for each layer are located at opposite ends of the sleeping pad.

According to one aspect of the present invention the upper layer of the sleeping pad is attached to the lower layer of the sleeping pad. Such a connection may be accomplished in different ways including by using several small welded tabs 110 arranged along the outer edges of the two layers as shown in FIG. 1, or any other fastening means. The welded tabs 110 ensure that the two layers 102 and 104 cannot significantly shift or be separated from one another during use.

FIG. 3 illustrates another embodiment of the present invention. In place of the welded tabs 110, shown in FIG. 1, semi-permanent, releasable fasteners 112 are used. Such releasable fasteners may be hook and loop fasteners or snaps or another similar fastener, which enables separation of the upper and lower pad layers 102 and 104 for packing purposes when the sleeping pad is not in use. Alternatively, the upper and lower layers, 102 and 104 may be attached by a drop thread method, by welding at different points than previously mentioned, or any other appropriate method.

FIGS. 4 and 7 illustrate yet another embodiment of the present invention. In this embodiment, upper and lower pad layers 102 and 104 share a separation layer 114 preferably made of an air impermeable material. The separation layer is in contact with a lower surface 122 of the upper layer 102 and an upper surface 124 of the lower layer 104. The separation layer 114 is air tight so that the different air pressures of the upper and lower layers 102 and 104 may be maintained. The material chosen for the separation layer 114 includes, but is not limited to, laminated or coated fabrics, polyesters, polyurethane film or another film material, Mylar or any other appropriate material. The separation layer 114 may be made from different material or the same material used in either an upper surface 118 of the upper layer 102, or the lower surface 120 of the lower layer 104. In addition, the separation layer 114 may be made of an insulating material and/or include a heat reflective material such as a thin metalized layer on at least one side of the separation layer 114. In addition, either or both of the top and bottom layers 102 and 104 of the dual-layer sleeping pad 100 may include a metalized layer for heat reflection.

In one embodiment, the lower layer 104 includes a foam material 115. In this embodiment, weight and bulk reducing channels 116 are shown disposed within the foam 115 that makes up the lower layer, 104. The channels or holes 116 run completely through the lower layer 104. Alternatively, the channels 116 may be disposed in upper layer 102, which may also include a foam material 115, the channels 116 may be disposed in layers, 102 and 104. The channels 116 reduce both bulk and weight and are therefore desirable to backpackers and hikers who actively seek to reduce the loads that they carry. It is contemplated and within the scope of the present invention that the foam material 115 may be present in either the top layer 102 or the bottom layer 104 or both the top and bottom layers 102, 104, as is shown in FIG. 7. It is also contemplated that the present invention would not include foam in either the top or bottom layers 102, 104.

As shown in FIG. 7, the foam material 115 preferably does not extend all the way into the end regions 170 of the dual-layer sleeping pad 100. As a result, the top layer 102, the bottom layer 104 and the separation layer 114 can all be easily connected to one another in the end region 170. The preferred connection method is a weld, wherein the top layer 102, the separation layer 114 and the bottom layer 104 are all welded together.

FIGS. 5 a and 5 b illustrate another embodiment of the present invention wherein either one of the upper or lower layers or both of the layers does not include foam and is provided in the shape of baffles (FIG. 5 a, 104 b and FIG. 6 b) or alternatively ribs (FIG. 5 b, 104 a and FIG. 6 a), to maintain structural integrity when inflated, such that the sleeping pad 100 stays flat or planar. The absence of the foam may reduce weight, while still providing additional cushioning and stability, while maintaining the user's ability to inflate the lower layer 104, 104 a or 104 b to a different pressure than the upper layer 102. The upper and lower layers, 102 and 104 of this embodiment of the present invention may be permanently or releasably connected as described above.

The material used on the lower surface 120 of the lower layer 104 is preferably more durable and abrasion-resistant than the material of the upper layer 102, since the lower layer 104 is in primary contact with the ground. Additionally, a softer micro-fiber type fabric is a preferred material for the upper surface 118 of the upper layer 102 since this surface is in primary contact with the user.

In a further embodiment of the present invention, FIG. 8, sleeping pad 200 features a top layer 202 and a bottom layer 204 separated by a separation layer 214. In this embodiment the separation layer 214 preferably includes insulation. The sleeping pad 200 includes an upper layer valve 206 and a lower layer valve 208. In this embodiment, multiple film layers are included and welded together to create a baffle configuration. The multiple film layers of the top layer 202 include an upper outer film layer 240, which forms the outermost upper surface of the sleeping pad. An upper baffle film layer 242 with a lattice structure is located below the upper outer film layer 240. An upper inner film layer 244 is located below the upper baffle film layer 242 and is also in contact with the separation layer 214. The multiple film layers of the bottom layer 204 include a lower outer film layer 246, which forms the outermost lower surface of the sleeping pad. A lower baffle film layer 248 with a lattice structure is located above the lower outer film layer 246. A lower inner film layer 250 is located above the lower baffle film layer 248 and is also in contact with the separation layer 214.

A plurality of connection points 260 are created, preferably by welding, wherein the upper baffle film layer 242, upper inner film layer 244, lower inner film layer 250 and lower baffle film layer 248 and separation later 214 are welded together. The combination of the lattice structure of the upper baffle film layer 242 and the lattice structure of the lower baffle film layer 248 and the plurality of connection points 260 form the baffle design as seen in FIG. 8. In this embodiment air that enters the top layer 202 through the upper layer valve 206 remains in the top layer 202 and cannot pass into the bottom layer 204. Similarly, air that enters the bottom layer 204 through the lower layer valve 208 cannot pass into the upper layer 204. The separation layer 214 extends all the way to ends 270 of the sleeping pad 200. Each end 270 of the sleeping pad 200 may be welded.

Accordingly, the present invention provides a novel, multi-layer sleeping pad having a top inflatable layer and a bottom inflatable layer, wherein the user can independently adjust the inflation level of the top layer independent from the inflation level of the bottom layer, allowing the user to customize their own comfort level based on sleeping conditions and terrain.

Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the allowed claims and their legal equivalents. 

The invention claimed is:
 1. A dual-layer, inflatable sleeping pad, comprising: an upper inflatable layer, wherein said upper inflatable layer is configured for being inflatable to a first user-selected inflation level; a lower inflatable layer, coupled to said upper layer, wherein said lower inflatable layer is configured for being inflatable to a second user-selected inflation level independent of said first user selected inflation level; a first inflation valve located on said lower inflatable layer and in fluid communication with said lower inflatable layer and configured to allow air to travel into and out of said lower inflatable layer; and a second inflation valve, located on said upper inflatable layer and in fluid communication with said upper inflatable layer and configured to allow air to travel into and out of said upper inflatable layer.
 2. The sleeping pad of claim 1, wherein said upper inflatable layer and said lower inflatable layer further comprise an open cell foam material.
 3. The sleeping pad of claim 2 wherein said open cell foam material of said at least one of said upper and lower inflatable layers include at least one hollow channel disposed through said open cell foam material.
 4. The sleeping pad of claim 1, wherein said upper and lower inflatable layers are coupled together using one of the methods selected from the group consisting of: a plurality of welded tabs, a plurality of semi-permanent, releasable fasteners and stitching.
 5. The sleeping pad of claim 1, wherein said first and second inflation valves are located on a same end of said upper and lower inflatable layers.
 6. The sleeping pad of claim 1, wherein said lower inflatable layer has an upper surface and a lower surface, wherein said lower surface is made from a durable and abrasion-resistant material.
 7. The sleeping pad of claim 6, wherein said upper inflatable layer has an upper surface and a lower surface, wherein said upper surface includes a fabric material.
 8. The sleeping pad of claim 1, further comprising a separation layer, wherein said separation layer is located between said upper inflatable layer and said lower inflatable layer.
 9. The sleeping pad of claim 8, wherein said separation layer is comprised of a metallic material.
 10. The sleeping pad of claim 8, wherein said separation layer is comprised of an insulation material.
 11. The sleeping pad of claim 1, wherein said upper layer comprises open cell foam and said lower layer comprises inflatable baffles.
 12. The sleeping pad of claim 1, wherein said upper layer comprises inflatable baffles and said lower layer comprises open cell foam.
 13. The sleeping pad of claim 1, comprising a middle layer disposed between said upper inflatable layer and said lower inflatable layer, said middle layer including metallic material.
 14. The sleeping pad of claim 1, wherein one of said upper inflatable layer and said lower inflatable layer further comprise an open cell foam material. 